Everything that needs to be measured to certain specifications falls within the scope of metrology, from the smallest products such as nuts, bolts and screws, spectacle frames and pens, to household appliances, aircraft, trains, cars, trucks and boats.
The manufacture of different modes of transport involves measuring each part to a very high level of precision and accuracy. The main challenge is to carry out these measurements at higher volumes, but the size of some parts is simply too large for them to be positioned on the shop floor.
In such situations, there is a growing demand for 3D measuring devices and metrology software applications that can not only provide effective measurements at high production volumes, but also adapt to the locations where parts are positioned, while being accessible and safe enough for metrologists to use.
The main challenges of large-scale metrology
When it comes to measuring parts for large-scale products, the very first challenge facing 3D metrology professionals is to take into account the scale and complexity of the measurement work involved.
Measurement of oversized parts
One of the main challenges for metrology professionals is to effectively measure parts that don’t pass through the quality lab and workshop, because they’re simply too big to fit. This applies in particular to parts belonging to various modes of transport, such as aircraft, trains and ships.
The quality of measurement of thousands of machined parts and assemblies must be of the highest standard, as this guarantees transport safety. This can be difficult to control directly on the shop floor.
Difficult angles of incidence or inaccessible features
Some parts may simply be too difficult to reach logistically and physically. If parts can’t be reached and accessed properly, it becomes less easy to guarantee measurement quality.
It can also be difficult to access parts that are physically inaccessible with the required 3D measuring equipment, which is an obstacle to measurement productivity.
Complex geometries and tighter tolerances
Some aircraft part inspections, such as wing spars, require a CMM capable of measuring large, complex geometries.
The ribs of an aircraft’s wings and center section, sub-assemblies such as airframes, or even entire sections of an aircraft need to be measured using a flexible, highly accurate measuring system, capable of adapting intelligently to their large proportions, and installed close to the production line to improve manufacturing cycle times.
Tough conditions on the shop floor
It is also essential to take into account uncontrollable external conditions, such as climate, temperature variations and humidity levels on the sites where the manufacturing plants are located.
Indeed, measuring equipment and complex parts are subject to high loads and stresses, which can compromise measurement quality if environmental conditions are less than optimal.
Invest in a large-scale 3D quality control solution
The good news is that there are now solutions to meet this growing demand for solutions to the complex metrological challenges associated with large-scale manufacturing projects.
The ideal 3D quality control solution for large-scale metrology projects should have the following features:
- Be fully compatible with all 3D measuring equipment used for large-scale inspection: this applies to the interfaces of all makes and models of large CMMs, laser trackers, laser radars and mobile optical systems.
- Support for all common and native CAD exchange formats, including CATIA.
- Extremely easy to use and running seamlessly at maximum performance: the solution must have evolved from years of programming experience with 64-bit operating systems.
- Exploiting all available memory and optimization features: superior software architecture for the best possible data quality.
- Importing and processing large CAD files and heavy point clouds: with larger volumes, 3D point cloud data must be processed without decimation.
- Multi-instrument networking: via a multi-connection mode, to achieve the best precision results by grouping together several instrument locations.
- Calculating instrument measurement uncertainty: this applies in particular where there are variations in external factors such as temperature and humidity.
- Tracking and managing raw data: with consistency, uniformity and efficiency.
- Efficiently facilitate flush and gap inspections: to assess critical factors such as aerodynamic performance and fuel efficiency.
- Remote viewing of measurement data in real time: with any portable device, such as a smartphone or tablet, at no extra cost.
The challenges of large-scale metrology, such as working with oversized parts, complex geometries, tighter tolerances and harsh external conditions, can be met and solved by investing in an intelligent, flexible, transparent and universal 3D metrology solution.